PARTS AND SERVICE MANUAL for DeWald COACH HYDRAULIC
Contents
1. ERLETERELE ktk Hid i SSOguJIPH q3en OOS OOOoD AAA Hid SSoueY x 6c9005 Hid Fl 4 EL OE L Hd ped uno E al PENE 1 03 428 8 ani 5 ECHO Hd Asse JOU dung ssousey 6 6005 bd ez 12 Diagram for systems with touchpad 140 1179 irin W 209 Hid uonisod ung 24 ul asnj 5 51 Aay ay Son zL MOUS 5 ac _ OPT AAAA gen eret at mE Burg 8 y Sey 2 uid suns Seu y gy 9 ud ye a6eyoa 10 42995 Harness PH 5018 x xx Heutral Saf puajxa euis spuas ang 000 LZPA Hid frayed zi SUIDOJ JO pue sx3elf 0 7j spipuaqps ayy 0 jeubirs spuas Jo peaysul aney Aew pipz pue 5002 239 ut YING IUOS y y S9 0bdl Hid YUEN 5590100 Apes Z30 34M S JEM enau pue ped uo s0 07 y Dongc vd Hd aqng fjajes 10 10 5gje1a2do uay jo1juo3 H HS 0 2 uid Guryied Aynumuo aney2. p UMS Ajajes LINAH GY uoriubi ag 5 guld E mE o 3 CEBELHU Hid a pass 27 Ways LI i 2 JIMS zz gul T UMS EJjnag z 99 060 Hid IPMS 3 amp 1 yed apis L spo ZSbFCEHHU IMS 1 55 1 08k 345 dij 385 ss3u eH 66500919 Pump harness Hid Od adins 43e qrw Hd 5005 Hid Asse Iynugduing 03 42218 334nn05 Azp pay Ra A CUO Et LE Wid 2905 sseuJeu 616008 9 Bd EZ 13 Diagnosing a cylinder for internal leakage The piston seal inside of a hydraulic cylinder can deteriorate over time due to normal wear contaminated fluid etc FIELD TECHNICIANS THAT DO NOT HAVE A GAUGE AND GATE VALVE TOOL CAN DIAGNOSE USING THE FOLLOWING METHOD Check only one cylinder at a time 1 Completely RETRACT suspected cylinder 2 Remove the EXTEND hose at the cylinder See page 7 for hydraulic diagram to determine EXTEND and RETRACT hoses 3 Push the RETRACT or IN switch for at least 10 seconds and note how much fluid is coming from the fitting A small amount to trickle is normal steady flow is not The pump will groan but hold the switch for as
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4. RNG T d p die di Leveling jack valves amp coils Dewald hydraulic diagram Extend top gt Extend top Driver side rear Driver side front Retract bottom Passe Retract bottom Retract Extend MJ 2 d 62 wn Qe i 4 P EN E 7 P x ES RN a A 1 M A Auxiliary cylinder Extend E Pra Retract HYDRAULIC DIAGRAM ESV Electric Solenoid Valve Triple ESV shown Extension Retraction ELECTRIC SOLENOID VALVE HYDRAULIC SCHEMATIC Extension Retraction P O check valve P O check valve is opened during extension by pressurized fluid from the extend side of the pump Retract hose port P O check valve is opened during retraction by pressurized fluid from the retract side of the pump Return to reservoir Extend hose From pump port Stem valve and 12vdc coil Stem valve is opened when 12V coil is energized with voltage a m Extend hose lt i i oi potty lt gt __ __ check Return to reservoir ae Stem valve n and 12V coil Retract hose port N Instructions for installing seal kit 800176 VA25400 O rings black 904 VA1100 O rings black 016 DN11027 QUU 12VDC motor d ie Put rounded side Rr shee c of washer towards we ae a ha
5. PARTS AND SERVICE MANUAL DeWald COACH HYDRAULIC LEVELING SYSTEMS with square footpads on jacks Manual system touch pad DN12558 Emergency Jacks Fully Retract Retract Retracted Retract O Jacks Mot Retracted All Extend Park Brake Not Set O Power Dewald Equiped with ASAC Automatic system touch pad 500629 Manual system touch pad 140 1179 PAI HP 4 d POWER GEAR LEVELING D e WAIT JACKS DOWM ENGAGE e PARK HELUTRAL EMGAGE e PARK BRAKE CAUTION BEAD AND UNDERSTAND OPERATORS MANUAL BEFORE C P V WW Dowergdea Page 3 4 5 6 Page 8 9 10 12 13 19 TABLE OF CONTENTS Before you operate the system Preventive maintenance and recommended fluids Manual retraction procedure Parts list Typical Dewald pump configuration and hydraulic diagram Instructions for installing o ring kit 800176 Wiring diagrams Diagnosing a Dewald cylinder for internal leakage Troubleshooting guide Warranty policy Do not use the Dewald hydraulic leveling system or air suspension to support the vehicle while under the coach or changing tires The hydraulic leveling system is designed as a leveling system only e Do not use the Dewald hydraulic leveling system as a jack or in conjunction with a jack It is highly re
6. If the problem follows the check valve change check valve Valve coils miswired Check wiring diagrams Jack s leaking Replace jack or have jack resealed Bad o ring in pump assembly Install o ring replacement kit 800176 see pg 8 26 Jacks will not retract pump does not B Check grounding of black wire coming directly out of 12VDC motor ad connection of motor ground wire at pump at the pump assembly Check for 12V at the pump assembly on the copper buss bar that ties solenoids A and B together If power is found jumper the two large posts on solenoid A to see if pump will run If pump does not run then continue trouble shooting system to isolate problem No power to pump assembly Check for continuity between green and black wires of 12VDC Motor or pump has failed motor If no continuity replace motor If continuity is found then replace pump motor assembly With any jack retract switch pushed small post of solenoid B Solenoid B faulty should show 12V If so then two large posts of solenoid B should have continuity across them If no continuity replace solenoid Orange wire pin 2 of control panel harness must have 12V while DN12558 any jacks are being retracted Check orange wire for continuity If no Sear E continuity repair wire or replace harness If no voltage is found on Eas pin 2 replace touch pad With any jack retract switch pushed small t
7. 58 COOOL VH Hd aqng 11 1170 Diagram for systems with touchpad 500629 140 Heutral Saf irin W SaM Aew Ajea pue puajxa nj jeubis spuas anjq au apeg zL qeu SWOOD IO put 0 OT SMISE jeuBis spuas aim ayy 2002 ur WING sauaeoa auris Hid VUE 5690100 ajes enau pue ped YING uo 10105 DUOC aqng uonisod au 51 Son Zp MOUS 5 Ajajes FINS 10 10 nedal 01u02 H OHS 03 2 uid 81 y Sey Ose z uid ans Harness PH 5018 AZb SEU y JI 9 ud 10 5327 o Aynurnuoa aney p AALS E 52 6 m past JOH Fuld LEBELEHIU past JOH Ways Ajajes ena zz mmn Hid YIUMS yed apis SV poguen 5302 e 95 Do UM gLz 245 di 225 00919 Pump harness ZEBELHO Od HIF Waa 0 42218
8. and orange passenger side rear wires of the 8 pin coach harness for continuity Repair wires or replace coach harness as necessary Communication error DN12558 _ 500629 Check that the black wire with white stripe is connected to good Communication error ground Check for continuity to ground on the black wires of the pump harness The purple yellow and orange wires of the 8 pin harness will show 12V when their respective buttons on the touch pad are depressed If no signal replace control box Faulty control If previous causes and actions do not apply replace controls Jack s will not hold pressure Touch pad ProbabeCause Corrective Action J Check all hydraulic hoses for visible leaks Check that all connections are tight Leaks somewhere in the system Diagnose and replace as necessary any faulty cylinders See page 11 for diagnosing suspected cylinders Sem aos are in vere postion valves are in manual override Siem aos are in vere postion until they stop If system has red knobs instead of set screws turn Turn slotted set screws at the end of the valves counterclockwise knobs until they snap back into position see pg 5 Faulty stem valve 0000000 siem Faulty stem valve 0000000 Swap the suspicious valve with one of the other good valves If the problem follows the valve change valve Faulty P O check valve Swap the suspicious check valve with a good check valve
9. component Fix Check the pressure switch signal Check to make sure that all connections are tight and properly connected Cycle power to reset If that does not work try replacing components individually starting with the wire harness then the touch pad and lastly the control 23 Troubleshooting the leveling system Note Information regarding Dewald slide out parts service and troubleshooting can be found in the Parts and Service Manual for Dewald Hydraulic Slide Out Systems Before starting to troubleshoot the system check all harness connectors for proper connection Also look for any loose or hanging wires and replace tighten or connect as necessary according to the wiring diagrams contained in this manual Use the wiring diagrams supplied in this manual to locate and identify leveling system components referred to in this troubleshooting guide Troubleshooting any Direct Current DC electrical system should be done with caution and by a trained technician Anyone unfamiliar with electrical systems should not attempt the troubleshooting procedures listed in this guide Failure to follow these guidelines could result in personal injury or even death System will not turn on and or on off indicator light will not illuminate Touch pad Probable Cause Batteries disconnected Reconnect batteries and or check connections Battery voltage below 10V Charge batteries or replace if necessary Coach ignition not in run po
10. long as 10 seconds If internal piston seal is good little to no fluid should be coming out of fitting 4 If at this point the seal has proven to be faulty then repair or replace cylinder If seal appears to be holding pressure continue with the diagnosis 5 Re attach the removed EXTEND hose 6 Completely EXTEND suspected cylinder If a vehicle lift is not accessible it may be necessary to park the coach over a service pit to get leveling cylinder completely extended without lifting coach T Remove the RETRACT hose at the cylinder 8 Push the EXTEND or OUT switch for at least 10 seconds and note how much fluid is coming from the fitting A small amount to trickle is normal steady flow is not The pump will groan but hold the switch for as long as 10 seconds If internal piston seal is good flow should be greatly reduced or stopped by then 9 Do this with each cylinder to determine a faulty cylinder Note 1 Rooms that take hours or days to start drifting must use the gauge diagnostic method Note 1 This process will greatly reduce your diagnostic times for the identification of potential bad cylinders Note 3 Cap or hold your finger over the pump fitting of the removed hose to avoid drawing air into the system 14 Diagnosing drifting rooms with a gauge and gate valve Probable Cause Corrective Action Check all hydraulic hoses for visible leaks Check that all connections are tight Leaks somewhere in the system D
11. 000000 19 1 DN12560 Pumphande J O 20 1 DK10650 _ diesel coaches 1 21 1 DN12738 Elbow 90 degree 22 1 WOI13200 Fitting T 23 1 500919 Harness pump see pg 10 used on pumps w 500629 touchpad 24 1 600072 Handpumpassy gt gt O 1 800176 Oring seal kit for Dewald pump assemblies see pg8 1 DN12558 Touch pad manual system not shown see front cover of manual _____ 1 500629 Touch pad automatic system not shown see front cover of manual _ 1 1401170 10 gt J AJ i Quantities vary by system Hose assemblies should be ordered by the length of the hose in inches EEE See page 7 for description and part numbers for ordering Dewald pump assemblies Note Information regarding Dewald slide out parts service and troubleshooting can be found in the Parts and Service Manual for Dewald Hydraulic Side Out Systems PUMP ASSEMBLIES Leveling and slide room pump assy s Square reservoir tanks Square reservoir tanks come in 6 and 8 quart sizes The length of the 6 qt tank is 12 and the 8 qt is 14 long PU12463 PU12464 PU12479 PU12598 PU13080 PU13081
12. 2V 4 If pin 6 is ground VAY Neutral safety wires shorted try grounding pin 2 If the control then operates repair or replace wires or neutral safety switch Parking brake wire shorted Ignition wire shorted System does not go to correct level position Probable Cause Corrective Action Controls need recalibrated Recalibrate controls according to Tip Sheet 153 Faulty control If previous causes and actions do not apply replace controls Touch pad lights are flashing Probable Cause Corrective Action Possible trouble code being displayed See Tip Sheet 184 for error code explanation 29 LIMITED WARRANTY Power Gear warrants to the original retail purchaser that the product will be free from defects in material and workmanship for a period of 5 years following the retail sales date later than 9 1 05 Labor to repair these components will be covered for two years Power Gear will at its option repair or replace any part covered by this limited warranty which following examination by Power Gear or its authorized distributors or dealers is found to be defective under normal use and service No claims under this warranty will be valid unless Power Gear or its authorized distributor or dealer is notified in writing of such claim prior to the expiration of the warranty period Warranty is transferable pending documentation of Original sale date of product THIS WARRANTY SHALL NOT APPLY TO Failur
13. IC LEVELING SYSTEM SET UP amp RECALIBRATION PROCEDURE Note The following set up and recalibration procedure is for control 500630 or 140 1170 used with touch pad 500629 Set Up Procedure Follow this procedure to reprogram a new zero point stored level position 1 Turn the ignition on and the touch pad on wait for the lights to stop revolving 1 Place a carpenter s level on the floor in the center of the coach 2 Manually level the coach by pushing the MAN button for 5 7 seconds until the light comes on beneath the button Push the front button until the jacks contact the ground Push the rear button until the jacks contact the ground Push the left and the right button to verify that all of the jacks are on the ground Using the carpenters level complete the leveling process manually by pushing the appropriate buttons on the touch pad Verify that the coach is level 3 Turn the ignition on and the touch pad off 4 Push the front button 5 consecutive times followed by the rear button 5 consecutive times within 10 seconds All of the LEDs on the touch pad will begin flashing This indicates that you have successfully returned the control box to zero mode 5 Push the retract button three consecutive times the new zero point has now been set 6 After the retract button has been pushed three times all of the LEDs on the touch pad will stop blinking except the On Off LED The On Off LED will flash for 20 seconds Wa
14. PU13631 PU13635 900945 900956 PU13358 PU13632 PU13633 PU13634 PU13636 PU13637 900951 Suppression module not used on systems with 500629 touch pad 6 quart pump assemblies 6 qt leveling only 3 valve 6 qt leveling 1 4 valve 6 qt leveling 2 5 valve 6 qt quad slide pump 4 valve 6 qt leveling 1 w diode on coil 4 valve 6 at leveling 2 w diode 5 valve 6 qt leveling 1 w fuse 4 valve 6 leveling 2 w fuse 5 valve DMI pumps with PG controls 6 qt leveling 2 w fuse 5 valve 6 qt leveling 1 w fuse 4 valve 8 quart pump assemblies 8 at leveling 2 w diode 5 valve 8 gt leveling 1 4 valve 8 qt leveling 1 w diode on coil 4 valve 8 gt leveling 1 w fuse 4 valve 8 qt leveling 2 5 valve 8 qt leveling 2 w fuse 5 valve 8 gt leveling 3 w fuse 6 valve w diode Assembly is built with diode harness on solenoids w diode on coil Assembly is built with diodes inline on room coils w fuse Assembly is built with fuse in line on red power lead for wall switches Typical Dewald pump configuration Note Various pump configurations exist including systems designed for leveling only leveling plus one slide room leveling plus 2 rooms and leveling plus 3 rooms The pump and hydraulic diagrams pictured below are for a leveling 2 slide room system Slide room valves amp coils 4 x 7 dE dl N ast s
15. amp 4 eM SN C92 3 VS S S S S S SS A A 5 Diesel coach 6 Gas coach mounting mounting bracket bracket 12 Stem valve 13 12VDC coil Po d E 24 Hand pump assy Valve coil assembly a 18 Hand pump e cartridge valve Air dump valve diesel coaches e matur 20 Air dump Valve m 21 Elbow 177 9 Solenoid 2 22 Fittin T Fitting Item Part Number Description DN12989 Jack assy 3 bore x 15 stroke diesel coaches DN12581 Jack assy 2 5 bore x 13 stroke gas coaches 1 6 2or4 DN12564 Bracket cylinder to frame mounting 11 0 1 1 11 6 2or4 DN14405 Bracket cylinder to frame mounting 160 amp amp h 8 1 PT1000 J Breahercap BE 10 1 DN12457 Pressureswitth O 11 DN13932 J PO checkvave gt 12 DN13933 Stemvalve gt 13 DN13937 12VDC col 14 1 BA30000 Cuberelay ________ 15 1 DN12649 Suppression module not used on pumps w 500629 touchpad amp 16 1 2OK215008 Pump motorassembly 17 1 DN11027 12VDCmotorony 0000000000 18 1 DN14866 Hand pump cartridge valve 0
16. bad cylinder Always install the gauge on the hoses hooked up to the outlined color side of the decal not the solid color side How do use the gauge and gate valve to find the exact location of the problem 1 Relieve pressure on the system by opening the hand pump valve counter clockwise knurled aluminum knob then open each of the solenoid valves by turning the sloted set screw clockwise until it stops 2 Assemble the gauge and gate valve as shown in the diagram Install it so that the gauge is between the gate valve and the pump 3 Shut off gauge s gate valve 4 Run pump to 2000 psi or more 5 Note how much pressure seeps off in 15 minutes Pressure should not go lower than 1750 psi If it goes lower than 1750psi the pump shuttle valve is bad and pump should be replaced Replacement pump part number is OK215005 does not include tank or manifold Hydraulic pressure gauge J 3000 To jack leg gt Gauge s gate valve Dewald leveling jacks pump assembly 17 systems using a single hydraulic cylinder per slide room If the pressure remains above 1750 for 15 minutes go on to step 6 6 7 ees Bc Relieve pressure on the system by opening the hand pump counter clockwise Move the gauge so that the gauge is between the gate valve and the cylinder on the retract hose Close the hand pump valve again Open the gate valve Retract jack completely mor
17. commended that should a tire need to be changed a trained professional should perform the service Attempts to change tires while supporting the vehicle with the hydraulic system could result in damage to the motor home and or cause serious injury or death CAUTION CHECK THAT POTENTIAL JACK CONTACT LOCATIONS ARE CLEAR OF OBSTRUCTIONS OR DEPRESSIONS BEFORE OPERATION CAUTION KEEP PEOPLE CLEAR OF COACH WHILE LEVELING SYSTEM IS IN USE CAUTION NEVER EXPOSE HANDS OR OTHER PARTS OF THE BODY NEAR HYDRAULIC LEAKS HIGH PRESSURE OIL LEAKS MAY CUT AND PENETRATE THE SKIN CAUSING SERIOUS INJURY CAUTION PARK THE COACH ON A REASONABLY SOLID SURFACE OR THE JACKS MAY SINK INTO GROUND ON EXTREMELY SOFT SURFACES USE LOAD DISTRIBUTION PADS UNDER EACH JACK CAUTION NEVER LIFT ALL THE WHEELS OFF THE GROUND TO LEVEL THE COACH DOING SO MAY CREATE AN UNSTABLE CONDITION BEFORE YOU OPERATE THE SYSTEM The leveling system shall only be operated under the following conditions The coach is parked on a reasonably level surface The coach PARKING BRAKE is engaged The coach transmission should be in the park or neutral position The ignition is in the run position or engine is running peur SYSTEM DESCRIPTION Please read and study the operating manual before you operate the leveling system The Dewald electro hydraulic leveling system consists of the following major components A Dewald supplies double acting jacks rated at a lifting ca
18. crews A on the front of the pump assembly clockwise until they stop This will hold the valves open Note Coaches that pre date 2001 may have a red knurled knob on the end of each valve A Instead of turning setscrew as instructed you simply pull out the red knobs and turn them 1 4 turn in either direction When you release them they will stay locked in the out position Turn the silver larger Knurled knob B on the front of the power unit 2 turns counter clockwise Insert the pump handle into the receptacle C and pump the hand pump When all the jacks and the slide out room s are fully retracted tightly close the silver knurled knob clockwise Turn each of the small slotted setscrews counter clockwise until snug Note If equipped with red knobs A turn them a turn to pop them back into normal operating position Chey B 67 6 0 0 _ JD Note Number of valves A shown will vary depending on how many slide rooms are operated by the pump assembly Please read the owners manual from the manufacturer who built and designed your motor home for further leveling and slide out room operating information and safety features PARTS LIST Typical Dewald pump assembly as viewed from behind _ Pump assembly front view 8 Breathercap __ Manifold assembly Ds hha m T a 7 Hose fittings Vd e er 11 P O check 220 2 6 di Item 1 Jack assembly includes items 2 3
19. d including hoses fittings and internal Loss of hydraulic pressure at pressure switch 500629 piston seals of cylinders Check label on control box for revision number example REV 1 Faulty controls Call Power Gear technical service at 800 334 4712 for information regarding current revision to control box 28 Emergency retract will not function when parking brake is released and or coach is put into gear Touch pad Probable Cause Corrective Action There must be 12V at copper buss bar that ties solenoids A and B together Check grounding of black wire coming directly out of 12VDC motor at Bad connection of motor ground wire at the pump assembly pump No power to pump assembly Pin 3 white wire with orange stripe of ignition harness must have continuity to ground when parking brake is engaged If parking brake DN12558 is released and continuity to ground is still found repair white wire with orange stripe or replace ignition harness ae Pin 2 yellow wire of ignition harness must show 12V signal when key 15 in run position When key is off the 12V signal should go away If signal is present while key is off repair yellow wire or replace ignition harness 500629 Improper wiring to 6 pin harness See Tip Sheets 195 196 197 199 200 204 205 Y Check for voltage at pin 6 at the 6 pin connector on the control box EO TAST AT If it has 12V make sure pin 2 also has 1
20. e due to normal wear and tear accident misuse abuse or negligence Products which are modified or altered in a manner not authorized by Power Gear in writing Failure due to misapplication of product Telephone or other communication expenses Living or travel expenses Overtime labor Failures created by improper installation of the product s slideout system or slideout room to include final adjustments made at the plant for proper room extension retraction sealing interface between slideout rooms and side walls synchronization of inner rails or improper wiring or ground problems Failures created by improper installation of leveling systems including final adjustments made at the plant or low fluid level wiring or ground problems Replacement of normal maintenance items There is no other express warranty other than the foregoing warranty THERE ARE NO IMPLIED WARRANTIES OF MERCHANTIBILITY OR FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL POWER GEAR BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES This warranty gives you specific legal rights and you may also have other rights which vary from state to state Some states do not allow the limitations of implied warranties or the exclusion of incidental or consequential damages so the above limitations and exclusions may not apply to you For service contact your nearest Power Gear authorized warranty service facility or call 1 800 334 4712 Warranty service can be perfo
21. e than 2000 psi shut off the gate valve Watch for falling pressure for 15 minutes If pressure falls more than 200lbs it indicates a bad piston seal or other external leak NOTE some seals leak slower than others If the room takes several days before drifting extend the time that you observe the cylinder retraction pressure Test each cylinder to find the exact source of the problem 4 Teoiinder Systems using hydraulic cylinders per slide room If the pressure remains above 1750 for 15 minutes go on to step 6 gt ee DU a a Relieve pressure on the system by opening the hand pump valve counter clockwise Move the gauge so that it is between the cylinders on the retract hose Close the hand pump valve again Open the gate valve Retract completely more than 2000 psi shut off the gate valve Watch for falling pressure for 15 minutes If pressure falls more than 200lbs it indicates a bad piston seal or other external leak NOTE The cylinder with the leak will be the one on the gauge side of the valve NOTE In order to prove that both cylinders are not leaking the gauge will have to be moved to the other side of the gate valve and the test repeated NOTE some seals leak slower than others If the room takes several days before drifting extend the time that you observe the cylinder retraction pressure Test each cylinder to find the exact source of the problem AW Wu 19 AUTOMAT
22. e the key off and then back on Mode Out of Level Tolerance Indication The following LED s are blinking together Left Right Front Rear and All Level Cause Coach is SO FAR out of level that jacks won t help OR Control was previously programmed at a position that was not level OR Control was not securely fastened in place when level was programmed Fix Move coach to ground that is more level If you know you are on fairly level ground then re program a new level position See page entitled AUTOMATIC LEVELING SYSTEM SET UP amp RECALIBRATION PROCEDURE Mode Wait Indication The Wait LED is blinking Cause The control is busy The LED will stop blinking in less than one minute 22 Low Voltage Indication The Low Voltage LED 15 blinking Cause The voltage is low at the control below 10 5 volts Fix Charge or replace the battery f a leveling procedure is being attempted the coach should be running to ensure a good voltage supply at the control Check the wiring to the control between wire 5 of the 6 pin connector and wire 1 of the 8 connector Voltage less than 10 5 volts needs appropriate repairs Mode Failure mode Indication The following LED s are blinking together Left Right and All Level Cause Retract timeout when retract is active for 2 minutes and pressure switch does not indicate jacks up OR Any internal failure could be caused by a poor connection or faulty
23. eck the brown wire of the 8 pin harness at the S control box for continuity to ground If no continuity replace pressure Faulty pressure switch Communication error 500629 Communication error Faulty pressure switch e 1 switch Faulty controls If previous causes and actions do not apply replace controls Jacks down light does not extinguish Touch pad Probable Cause Corrective Action Check that brown wire from control box is connected to green wire w black stripe from pressure switch Reconnect as necessary 500629 The pressure switch is normally a closed circuit but opens when mmm reme jacks get to complete retraction and the pressure in the manifold EINE builds to over 1400 PSI With jacks fully retracted and proper OAO Faulty pressure switch pressure in the manifold check the brown wire of the 8 pin harness at the control box for continuity to ground If continuity to ground is found on brown wire while jacks are completely retracted and proper manifold pressure is evident replace pressure switch Faulty controls If previous causes and actions do not apply replace controls Jacks down light and alarm will come on while driving jacks are fully retracted Touch pad Probable Cause Communication error Pressure switch is opened when the jacks are fully retracted and the pressure in the manifold builds to 1400 PSI Identify any leaks on the retract side of the manifol
24. erminal of solenoid B should show 12V If not check for voltage at terminal E of suppression module If no voltage replace suppression module No signal to solenoid B from suppression module M Green wire from control box to small terminal of solenoid B will C show 12V when any jacks are being retracted Check green wire LG for continuity If no continuity then repair green wire or replace harness Communication error Jack s will not retract pump is running Touch pad Probable Cause Corrective Action Drain tank to proper level See Preventive Maintenance and Recommended Fluids pg 3 Check for continuity across the two yellow wires coming out of each of the 1 2 and 3 coils If no continuity replace coil s Check for 12V on the brown L amp R front pin 5 blue driver side rear pin 8 and grey passenger side rear pin 11 wires of the 14 pin control harness while pushing the all retract switch If no 12V signal check the continuity of each of these wires between the touch pad and suppression module Good wires bad touch pad If any of these wires has no continuity then repair wires or replace harness Terminals A passenger side rear jack B driver side rear jack and C front jacks transfer the signal from the touch pad to the coils If no 12V signal is present at these terminals when jack s are being retracted replace suppression module Faulty suppression module Check
25. for continuity to ground on terminals and J If no continuity on all of these terminals then check that the black wire from suppression module is connected to good ground If black wire is connected to ground but there is no continuity to ground on terminals I and J then replace suppression module Check for 12V on the purple L amp R front yellow driver side rear and orange passenger side rear wires of the 8 pin coach harness while the jack retract button is pressed If no 12V signal check the continuity of each of these wires between the control box and pump 500629 assembly Good wires bad control box If any of these wires has no continuity then repair wires or replace harness Check that the black wire with white stripe is connected to good ground Check for continuity to ground on the black wires of the pump harness The purple yellow and orange wires of the 8 pin harness will show 12V when their respective buttons on the touch pad are depressed If no signal replace control box Faulty control If previous Causes and actions do not apply replace controls System overfilled with fluid Faulty coil s Communication error 0312558 BOA VE Communication error Jacks do not retract completely Touch pad Probable Cause Corrective Action The pressure switch is normally a closed circuit While jacks are Faulty pressure switch extended check the gree
26. iagnose and replace as necessary any faulty cylinder Turn slotted set screws at the end of the valves counterclockwise until they stop If Stem valves are in manual override position um red knobs instead of set screws turn knobs until they snap back into Swap the suspicious valve with one of the other good valves If the problem Faulty stem valve follows the valve check for bad o rings on the tip of the valve If o rings are OK change valve Swap the suspicious check valve with a good check valve If the problem follows Faulty P O check valve the check valve check for damaged o rings If the o rings are OK change check valve Valve coils miswired Check wiring diagrams Cylinder s leaking Replace cylinder or have cylinder resealed Bad o ring in pump assembly Install o ring replacement kit 4800176 Ap OE q o i t cise a A 2 vor T 4 3000 psi Gauge showr disconnect for connecti Gauges assembled as shown here will be the most versatile for all applications 15 This gauge is installed onto the retract side of the 5 manifold This will show if any portion of the system has a problem It will not show you where the problem is however The benefit of checking like this is that the gauge can be installed without a mess it is Gauge is shown as it would be installed on a pump checking a
27. it until the light stops blinking then turn the key switch off The control has now been reprogrammed 20 Power Gear Leveling Controls 500630 Rev 2 and higher 140 1170 amp 500674 Rev land higher Error Codes An error code is indicated by certain LEDs on the touch pad blinking in a given pattern Find the pattern you are seeing under Indication in the chart below to find the mode Then find the Mode in the paragraphs that follow to find a fix for the problem Note 500630 and 140 1170 controls are used with the 500629 touch pad The 500674 control is used with the 500675 touch pad Note Any reference to the A Level LED refers to the green Power Gear LED in the center of the diamond pattern During normal operation this LED comes on to indicate that the coach is level Indication blinking LEDs Modes Level Already Level On Off Jacks Down amp Park Brake Panel Communication Error Park Brake Park Brake signal haws been lost Wait amp On Off Transmission neutral signal has been lost All of the LEDs are blinking and a buzzer is on and the jacks are retracting All of the LEDs are blinking Zero Mode Left Right Front Rear amp All Level Wait Low Voltage Left Right amp All Level Emergency Retract Out of Level Tolerance Wait Low Voltage Failure Mode Mode Panel Communication Error Indication The following LEDs are blinking together On Off Jacks Down amp Pa
28. n as a button is pushed Neutral safety wires shorted Voltage must remain above 10V while in operation Check battery Low system voltage condition and connections 24 or all jacks will not extend pump does not Check grounding of black wire coming directly out of 12VDC motor ad connection of motor ground wire at pump at the pump assembly Check for 12V at the pump assembly on the copper buss bar that ties solenoids A and B together If power is found jumper the two large posts on solenoid A to see if pump will run If pump runs then continue trouble shooting system to isolate problem No power to pump assembly Check for continuity between blue and black wires of 12VDC motor Motor or pump has failed If no continuity replace motor If continuity is found then replace pump motor assembly With any jack extend switch pushed small post of solenoid A Solenoid faulty should show 12V If so then two large posts of solenoid A should have continuity across them If no continuity replace solenoid With any jack extend switch pushed small post of solenoid A No signal to solenoid A from cube relay should show 12 If not check for voltage at terminal 30 of cube relay If no voltage replace cube relay Set brake park brake not set light should go out If brake is set and light does not extinguish check for continuity to ground at the orange wire with white stripe on the 6 pi
29. n connector If continuity to ground is found then replace touch pad If there is no continuity the switch is bad the parking brake is not set or the wires to the switch are bad Yellow wire of 6 pin ignition harness must show 12V when the key B E 9 9 is in the run position Check and repair wire as necessary Purple wire of control panel harness must have 12V while any jacks are being extended Check purple wire for continuity If no continuity repair wire or replace harness If no voltage is found on ourple wire replace touch pad With any jack extend switch pushed terminal 87a of cube relay should show 12V If not check for voltage at terminal F of Parking brake not set wire not grounded or faulty parking brake switch Communication error No signal to cube relay from suppression module suppression module If no voltage replace suppression module Coach is parked on an excessive slope Move coach to a more level area coach 15 already parked on a known level area then the control box needs calibrated see TIP sheet 153 Blue wire from control box to terminal 87a of cube relay will show Communication error 12V when any jacks are being extended Check blue wire for continuity If no continuity then repair blue wire or replace harness All four orange level lights and center green all level light are blinking 25 or all jacks will not exte
30. n wire w black stripe on the pressure switch for continuity to ground If no continuity replace switch Jacks retract and pump starts again a few seconds after full retraction Touch pad Probable Cause Corrective Action Check label on control box for revision number example REV 1 Faulty control box Call Power Gear technical service at 800 334 4712 for information regarding current revision to control box Jacks fully retracted light does not illuminate Touch pad Probable Cause Corrective Action The pressure switch 15 normally a closed circuit to ground but opens when jacks get to complete retraction and the pressure in the manifold builds to over 1400 PSI With jacks fully retracted and proper pressure in the manifold green wire w black stripe on pressure switch should not have continuity to ground If continuity to ground is found on green wire with black stripe while jacks are completely retracted and proper manifold pressure is evident replace pressure switch Check green wire pin 3 of control panel harness for continuity If no continuity is found repair wire or replace harness Jacks down light does not illuminate Touch pad Probable Cause Corrective Action Check that brown wire from control box is connected to green wire w black stripe from pressure switch Reconnect as necessary A 7p The pressure switch is normally a closed circuit to ground While Adi NT jacks are extended ch
31. nd pump is running Fill tank to proper level See Preventive Maintenance and Low fluid level Recommended Fluids pg 4 The silver knurled knob on the hand pump 15 Knurled knob must be turned clockwise for normal operation open Faulty coil s Check for continuity across the two yellow wires ie out of each y of the 1 2 and 3 coils If no continuity replace coil s Valve coils miswired Check wiring diagrams Check for 12V on the brown L amp R front blue driver side rear and grey passenger side rear wires of the 14 pin control harness while pushing the all extend switch If no 12V signal check the continuity of each of these wires between the touch pad and suppression module Good wires bad touch pad If any of these wires has no continuity then repair wires or replace harness Check for continuity to ground on terminals and J If no continuity on all of these terminals then check that the black wire from suppression module is connected to good ground If black wire is connected to ground but there is no continuity to ground on Faulty suppression module terminals H and J then replace suppression module Terminals A passenger side rear jack B driver side rear jack and C front jacks transfer the signal from the touch pad to the coils If no signal is present at these terminals when jack s are being extended replace suppression module Check purple L amp R front yellow driver side rear
32. nd pump ae p 2 VA14350 O ring thick EMEN da 4 b X lt ut install this in the groove Cartridge y SE x e OK21500S pump motor 55 6000725 hand pump assy Torque to 70 in Ibs f DN10672 lift tube N V Wf VA25300 O ring install this o rin Pd m around the edge J Seal kit 800176 contains the following parts Qty Part 2 VA110 00 2 VA143 50 2 VA200 00 1 VA253 00 4 VA25400 Return all rooms and leveling legs to the travel storage position Disconnect the battery for the coach and pump system Drain the tank of oil with a siphon Mark each hose and wire for their respective positions Remove each hose from the pump assy and insert the ends into a bucket in case of leakage Remove the power leads to the pump motor green blue and black Remove the pump from its mounting bracket Take it to a clean well lighted workbench for disassembly Remove the tank drain any remaining fluid and clean inside of tank with a lint free cloth Remove the hand pump from the assembly by removing the two nuts and lock washers Removal may be difficult with the inlet strainers in place While pulling the hand pump off of the hollow tubes pivot the hand pump down to clear the strainers after it clears the tubes 10 Insert a long Allen wrench small enough to fit through the holes in the hollow tubes to check them to make sure they are tight right hand thread 11 Clean
33. pacity appropriate for your coach Each jack has a large 8 square 64 square inch shoe for maximum surface area on soft surfaces B Each jack is powered extension and retraction from a central 12 VDC motor pump assembly which also includes the hydraulic oil reservoir tank control valve manifold and solenoid valves C The electronic controls located in the coach control the hydraulic pump There are 2 different control systems e A Manual control system e Automatic control system with internal leveling sensor Check the fluid level every month Check and or fill the reservoir with the jacks and room s in the fully retracted position The fluid should be within 1 2 inch of the top of the reservoir tank Change fluid every 24 months Inspect and clean all hydraulic pump electrical connections every 12 months Remove dirt and road debris from jacks as needed If jacks are down for extended periods it is recommended to spray exposed leveling jack rods with a silicone lubricant every 5 to 7 days for protection If your coach is located in a salty environment within 60 miles of coastal areas it is recommended to spray the rods every 2 to 3 days with a silicone lubricant ME 99 Typical Dewald pump assembly as viewed from behind Fill port breather cap RECOMMENDED HYDRAULIC FLUIDS FOR YOUR DEWALD HYDRAULIC PUMP The fluids listed here are acceptable to use in your
34. pump assembly Your system was originally filled with 15046 type hydraulic oil 10 wt It is not recommended that hydraulic fluid and automatic transmission fluids be mixed in the reservoir In most applications Type A automatic transmission fluid ATF Dexron Ill etc will work satisfactorily Mercon V is also recommended as an alternative fluid for Dewald hydraulic systems If operating in cold temperatures less than 10 F the jacks may extend and retract slowly For cold weather operation fluid specially formulated for low temperatures may be desirable Mobil DTE 11M Texaco Rando HDZ 15HVI Kendall Hyden Glacial Blu or any Mil Spec H5606 hydraulic fluids are recommended for cold weather operation Please consult factory before using any other fluids than those specified here WARNING Your coach should be supported at both front and rear axles with jack stands before working underneath failure to do so may result in personal injury or death MANUAL RETRACTION PROCEDURE Note Please read the entire Operations manual for Dewald hydraulic leveling systems before operating this system Your Dewald Hydraulic Power System has been designed to operate both the leveling and slide out system from one power source This power unit has a built in hand pump for manually retracting the jacks and slide out room s if complete power should be lost to your leveling system Hand Pump Operation 1 Turn each of the small slotted sets
35. rk Brake Cause Poor connection between components or faulty component Fix Check to make sure that all connections are tight and properly connected Cycle power to reset If that does not work try replacing components individually starting with the wire harness then the touch pad and lasily the control Mode Park Brake Indication Park Brake LED is blinking Cause Park brake is not engaged OR improper wiring of the parking brake wire Fix Engage park brake If that does not work check the wiring of the park brake wire 21 Mode Emergency Retract Indication Buzzer is on all of the LEDs are blinking and the jacks are retracting Cause While the jacks are down and the ignition is in the run position the parking brake is disengaged OR Improper wiring of the parking brake wire s OR loss of pressure switch signal Fix Engage park brake and make sure coach is not in gear while the jacks are down or while extending jacks Check the signal from the pressure switch se wiring and trouble shooting guides If problem persists check the wiring of the parking brake wire s Mode Zero Mode Indication All LEDs are blinking together Cause Unit is brand new OR user put system into this mode Unit is waiting for a programmed level position Fix See page entitled AUTOMATIC LEVELING SYSTEM SET UP amp RECALIBRATION PROCEDURE If unit is not brand new and you want to keep the previously stored level position cycl
36. rmed only by a Power Gear authorized service facility This warranty will not apply to service at any other facility At the time of requesting warranty service evidence of original purchase date must be presented Power Gear 1217 E 7 Street Mishawaka IN 46544 800 334 4712 WWW powergearus com 30
37. sition Turn ignition to run position 6 pin harness not plugged in properly Check 6 pin harness for proper connection Pin 4 of the 6 pin connector must have 12V with the ignition in the No power to touch pad run position Check for blown fuse on the red wire of the 6 pin connector Replace fuse with a 6 25 amp Slo Blo fuse if necessary E Grane wile Se obs ied the 6 pin connector is a ground wire Test for continuity with Faulty control If previous causes and actions do not apply replace the touchpad Transmission not in park or neutral Place transmission in park or neutral Parking brake notset Setbrake _________ _______________ Control has been left on for more than four Turn off the touch pad and then turn back on minutes auto shut off 500629 Ground wire disconnected or shorted eund the 8 pin connector is the ground Test for continuity with DN12558 Check for voltage at pin 6 of the 6 pin connector on the control If it has 12V make sure pin 2 also has 12V If it is ground try grounding pin 2 If the control then operates repair or replace wires or neutral safety switch Check continuity between pin 1 of the 6 pin connector and ground If un Sila oda there is no continuity the switch is bad the parking brake 15 not set or the wires to the switch are bad Faulty control If previous causes and actions do not apply replace the controls System turns on but shuts off as soo
38. the components before re assembly 12 Install 2 new o rings VA25400 onto each tube 4 total lubricate them with Dexron 13 Re install the hand pump onto the pump assy 14 Install one white o ring VA20000 onto each of the two tubes Push the assembly together as much as possible to align the housing and tubes so the o rings will be seated correctly 15 Re install the nuts onto the tubes and tighten to 70 inch pounds 16 Install new o rings VA14350 and VA25300 1 each onto hand pump assembly and re install the tank 17 Re install the pump components in reverse order of disassembly making sure to match the hose and wire markings 18 Re fill the tank with Dexron 111 fluid until 2 from the top of the tank 19 Run the rooms and or leveling legs to full extension wait 30 seconds and retract the rooms and leveling legs Repeat this 4 times This should completely purge air from the system 20 Check the fluid level in the tank with all rooms and jacks retracted Fill to proper level if necessary 21 Test the system for proper operation leaks etc Sec Ps ONT Note Some systems do not require The two 2 VA25400 o rings One 1 extra VA14350 o ring is included in the kit 10 ith touchpad DN12558 iagram for systems w D irin W H d 5 ways T Hid spo 394c HU H d uaa CEBELHU Hid zanen 42943 Od Lote Hid MS ansad adis
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